Removal Procedure
- Disconnect the negative battery cables. Refer to
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
in General Information. - Remove the engine cover. Refer to Interior Trim.
- Remove the air cleaner assembly and air intake duct.
- Remove the CDR vent hose.
- Remove the fuel lines and brackets.
- Remove the electrical harness and all electrical connections and brackets.
- Remove the transmission oil level indicator tube.
- Remove the engine oil indicator tube and bracket.
- Remove the rear air conditioning (A/C) line, if equipped.
- Evacuate the A/C system. Refer to HVAC.
- Remove the upper intake manifold.
- Remove the glow plug relay.
- Remove the lower intake manifold studs and fuel line clips.
- Remove the intake manifold and the gaskets.
- Clean the gasket surfaces on the lower intake manifold.
- Clean the gasket surfaces on the cylinder heads.
Important: Do not attempt to remove the center intake manifold with the left and the right intake manifolds as an assembly. Damage to the intake gaskets, center intake manifold and the turbocharger may occur during reassembly.
Important: Mark the following components in order to ensure proper reinstallation:
• The fuel line clips • The lower intake manifold studs • The brackets
Installation Procedure
- Install the lower intake manifold and gaskets.
- Install the intake studs and the fuel line clips. Apply teflon sealer or equivalent to the intake manifold bolts.
- Install the fuel line brackets and the ground straps.
- Install the electrical harness.
- Install all the electrical connections and the brackets.
- Install the transmission oil level indicator tube.
- Install the engine oil level indicator tube.
- Install the CDR vent hose.
- Install the upper intake manifold.
- Install the rear A/C lines, if equipped. Recharge the A/C system. Refer to HVAC.
- Install the glow plug relay.
- Install the engine cover.
- Connect the negative battery cable.
Tighten
Tighten the lower intake manifold studs to 42 N·m (31 lb ft).
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Important: Always replace the O-ring between the upper intake manifold and the turbocharger. Coat the O-ring with clean engine oil before installing.
